Breathable impact absorbing cushioning and constructions

ABSTRACT

Disclosed herein are breathable and conformable protection pads, which can be integrated into articles such as clothing and protective cases.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of commonly-owned andco-pending U.S. application Ser. No. 14/375,091, filed on Jul. 28, 2014,which is a 371 of PCT/US13/23480 filed on Jan. 28, 2013, which claimsthe benefit of U.S. Provisional Application No. 61/591,902, filed onJan. 28, 2012, and which is a continuation-in-part of commonly-owned andco-pending U.S. application Ser. No. 13/208,229, filed on Aug. 11, 2011,each of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The disclosure relates to breathable and conformable protection pads,articles that include such pads, methods of making and using the padsand articles and, in particular, to breathable and conformableprotection pads for humans, for areas that require free range of motion.

BACKGROUND

Many activities, especially athletic activities, involve potential riskto the body from impact. Elbows, knees, shoulders, ankles, hips andother joints can be especially susceptible to impact damage and yet arechallenging to protect without restricting the range of motion andmovement of the individual. Impact protection can be heavy,non-breathable or restrictive, or alternatively does not target certainbody parts accurately, or does so inconsistently.

Some impact protection systems consist of separate rigid pads that areheavy, and restrict motion. The rigid components can be lined with someform of soft cushioning to make them comfortable against the body, whichis an attempt to cushion impacts to the body, but the extra layers addto the weight and discomfort of the pads. In addition, the paddingsystems can be hot to wear, and also restrict the evaporation ofmoisture and sweat.

Other protective pads are made from materials that are softer, so theybend, but offer little in the way of protection against a seriousimpact, especially an impact from a rock or other hard object. Thesematerials include standard chemically foamed polyether or polyesterfoams.

Other padding can be made from stiffer foam materials, such ascross-linked polyethylene foams or EVA foams. Such foams offer a bitmore protection, but restrict the user's range of motion. Overall, suchmaterials offer insufficient protection, while restricting motion.

There also have been attempts to use stiffer foams as pads, but the foamhad to be cut in strips in order to reduce the restriction of movementthat a solid foam piece would cause. Unfortunately for the wearer, thestrips offered less than optimal protection.

Foam can also be thermoformed into curved or complex shapes, and sewnbetween layers of material that holds the strips or pieces in place.Other materials that offer better impact absorption such as d30 havealso been used in padding, but these materials are also stiff.

Attempts have been made to make the foregoing materials appear lessstiff to the wearer by creating thinner regions in each piece whichallows better flexing. But protective pads manufactured this way cannotoffer full range of motion at the location of the padding, because thematerial breaks apart when flexed at the thinner areas. These materialsalso need to be buried beneath layers of fabric because they are notdurable or aesthetically pleasing enough to be exposed. The use ofcovering materials adds unnecessary weight to the padding, and increasesthe cost of the pads.

A need exists for improved breathable, protective padding, particularlyfor areas requiring range of motion, and for joints.

SUMMARY

Disclosed herein, in one embodiment, is a breathable cushioning pad. Thecushioning pad includes an upper layer with an upper surface, a lowerlayer with a lower surface, and a cushioning material disposed betweenthe upper layer and the lower layer. The cushioning pad has a thickness.A channel can be disposed in the cushioning pad and defines a cushioningregion having a thickness. The channel includes a thickness less thanthe thickness of the cushioning region. At least one vent extendsthrough and is in fluid connection with the upper surface and the lowersurface.

In another embodiment, the breathable cushioning pad includes a groovedefined in the upper surface of the cushioning region. The groove has athickness less than the thickness of the cushioning region and greaterthan the thickness of the channel.

In another embodiment, the breathable cushioning pad includes a flange,and a channel adjacent to the flange. The channel has a thicknessgreater than the thickness of the channel and less than the thickness ofthe cushioning region.

In another embodiment, the breathable cushioning pad includes at leastone vent extending through and in fluid connection with the uppersurface and the lower surface of the pad. In another embodiment, thebreathable cushioning pad includes a vent disposed in the channel.

In another embodiment, the breathable cushioning pad includes Disclosedherein, in one embodiment, is a breathable cushioning pad, comprising acushioning region comprising an upper surface, a lower surface, athickness and a width. The cushioning region comprises a cushioningmaterial disposed between and continuously bonded to a continuous upperlayer and a continuous lower layer. A channel is disposed around anddefines the cushioning region. The channel comprises a thickness lessthan the thickness of the cushioning region. The channel furtherincludes the continuous upper layer and the continuous lower layer, andthe continuous upper layer is at least partially bonded to thecontinuous lower layer. At least one vent extends through and is influid connection with the upper surface and the lower surface.

In another embodiment, the breathable cushioning pad may include atleast one vent extending through and in fluid connection with the uppersurface and the lower surface of the channel.

In another embodiment, the breathable cushioning pad may include agroove defined in the upper surface of the cushioning region, and thegroove may have a thickness less than the thickness of the cushioningregion and greater than the thickness of the channel.

In another embodiment, the breathable cushioning pad may include aperimeter flange and a perimeter channel. The perimeter flange can bespaced apart from the cushioning region by the width of the perimeterchannel. The perimeter flange can have a thickness greater than thethickness of the perimeter channel and less than the thickness of thecushioning region. In another embodiment, the perimeter channel mayinclude at least one vent extending through and in fluid connection withthe upper surface and the lower surface of the perimeter channel.

In any of the embodiments of the cushioning pad, the continuous upperand lower layers can comprise a polyester thermoplastic polyurethane.

In any of the embodiments of the cushioning pad, the upper and lowerlayers can comprise a TPE film bonded to a layer spandex fabric, suchthat the TPE layers are disposed adjacent to the cushioning material.

In any of the embodiments of the cushioning pad, the cushioning materialcan comprise a cellular material comprising a plurality of cells havinga minimum cell diameter, and the thickness of the cushioning materialbetween the inner layer and the outer layer is less than the minimumcell diameter.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent fromthe following more particular description of exemplary embodiments ofthe disclosure, as illustrated in the accompanying drawings, in whichlike reference characters refer to the same parts throughout thedifferent views. The drawings are not necessarily to scale, emphasisinstead being placed upon illustrating the principles of the disclosure.

FIG. 1 is a top view of a section of one embodiment of a cushioning padaccording to the present disclosure, including a plurality of squarecushioning medallions;

FIG. 2 is a perspective view of the cushioning pad section shown in FIG.1;

FIG. 3 is a bottom view of the cushioning pad section shown in FIG. 1;

FIG. 4 is a top view of one of the square cushioning medallions formingpart of the cushioning pad shown in FIG. 1, showing a centrally located“vent”;

FIG. 5 is a perspective view of the square cushioning medallion shown inFIG. 4;

FIG. 6 is a cross-section of the square cushioning medallion shown inFIG. 4;

FIG. 7 is a cross-section of a section of the cushioning pad sectionshown in FIG. 1;

FIG. 8 is a top view of a section of another embodiment of cushioningmaterial according to the present disclosure, which comprises aplurality of vents disposed between the medallions;

FIG. 9 is a bottom view of the cushioning material section shown in FIG.8;

FIG. 10 is a perspective view of a section of another embodiment ofcushioning material according to the present disclosure, which comprisesa plurality of linear vents disposed between the medallions;

FIG. 11 is a top view of the cushioning material section shown in FIG.10;

FIG. 12 is a bottom view of the cushioning material section shown inFIG. 10;

FIG. 13 is a top view of an alternative embodiment of the squarecushioning medallion shown in FIG. 4, which includes airflow channelsextending from and fluidly connecting the outer sidewalls of themedallion to the vent sidewalls;

FIG. 14 is a perspective view of the cushioning medallion shown in FIG.13;

FIG. 15 is a cross-section of the square cushioning medallion shown inFIG. 13;

FIG. 16 is a top view of an alternative hexagonal cushioning medallion,which includes a central vent and airflow channels extending from andfluidly connecting the outer sidewalls of the medallion to the ventsidewalls;

FIG. 17 is a perspective view of the cushioning medallion shown in FIG.16;

FIG. 18 is a cross-section of the square cushioning medallion shown inFIG. 16;

FIG. 19 is a top view of an alternative octagonal cushioning medallion,which includes a central vent;

FIG. 20 is a top view of an alternative octagonal cushioning medallion,which includes a central vent and airflow channels extending from andfluidly connecting the outer sidewalls of the medallion to the ventsidewalls;

FIG. 21 is a cross-section of the square cushioning medallion shown inFIG. 20;

FIGS. 22-23 show top and cross-sectional views of one embodiment of anexemplary elbow pad comprising a plurality of vents extending from andfluidly connecting the front and backsides of the elbow pad;

FIGS. 24-25 show top and cross-sectional views of another embodiment ofan exemplary elbow pad comprising a plurality of vents extending fromand fluidly connecting the front and backsides of the elbow pad;

FIG. 26 shows top and cross-sectional views of another embodiment of anexemplary elbow pad comprising a plurality of curvilinear ventsextending from and fluidly connecting the front and backsides of theelbow pad; and

FIG. 27 is a table listing exemplary ranges for various dimensions ofthe pads according to the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present disclosure is directed to a breathable and conformingprotective cushioning pad, to items comprising the pads, and to methodsof making and using the pads.

The present pads include cushioning regions of various shapes, sizes,configurations and thicknesses. For ease of discussion, the terms“cushioning region” and “medallion” will used interchangeably throughoutthe description. Various materials can be used for the medallions, aswill be described below. The medallions are spaced apart by channels ofvarious depths and configurations, which define the perimeter of themedallions, and function as flexible “hinges”. The present pads cancomprise at least one vent disposed in one or more of the medallions,one or more of the channels, or in one or more of both of the medallionsand channels. The vents can various shapes, sizes, configurations andthicknesses. The vents allow airflow to and from opposite sides of thepad, which provides breathable characteristics to the pads, and togarments that comprise the pads, as well as reducing the weight of thepads. Therefore, such garments allow body moisture and vapors to bereleased, so they can be used for activewear without overheating orfeeling discomfort.

The surface of the medallions also may include channels and/or groovesof various depths and configurations, which define, in part, thecontours of the medallions, and provide some ventilation. In someinstances, a perimeter flange may be provided, spaced apart from theperimeter of the pad.

The combination of the medallions, vents, channels, grooves and flange,as well as the materials from which the pads are formed, togetherprovide various functional characteristics to the pad. For example, thechannels are deeper than the grooves, and are configured to provideunrestricted, free range of motion in critical areas, such as aroundjoints. The grooves are shallower than the hinges, and provideflexibility, while retaining some cushioning and/or impact resistance.However, it should be understood that both the channels and the groovesfunction as “hinges,” which increase the articulation of the pad.

The present cushioning pads can be incorporated into clothing, and canbe designed to have specific functional characteristics. Such clothingis unique in its ability to provide protection to areas of the body thatflex, particularly joints. The padding can be incorporated into garmentsin a unique way, such that garment materials fit snugly, but stretch andconform to the body, or to a specific joint shape, resulting in anintegrated padding system that protects the wearer from impact betterthan other products, because the pad is in constant and close, ordirect, contact with the wearer during the full range of motion.Garments incorporating the present pads provide improved protection frominjury when worn, because the base of the pad, or the material to whichthe base of the pad is attached, can be maintained in direct contactwith the user's body during use, when incorporated into clothing thatstretches and fits snugly, such as compression clothing. The flexibilityof the pads allows the pads to conform to a user's body shape, so thatthe pad can be maintained in contact with the user's body. That is,without the degree of flexibility of the present pads, the pads wouldnot be capable of conforming to the changing body contours of the user,while in motion. For ease of discussion, the term “flexible,” as usedherein, means the ability of the pad to move by bending, twisting,flexing and/or stretching, and the like.

By combining specific shapes, sizes, configurations, contours andorientations of the medallions, hinges, grooves and/or a perimeterflange, with specific pad and clothing materials, garments can bedesigned to maximize a user's free range of motion, while protectingspecific, targeted areas of the body, particularly joints. Such garmentsare aesthetically pleasing, more durable, lower in cost, more breathableand comfortable, and provide significant range of motion and targeted,accurate, protection to the body.

Similarly, the present cushioning pads can be incorporated into otheritems, such as protective cases. For example, the padding can beincorporated into sleeves or cases that correspond to the shape and sizeof an electronic device, such as a laptop computer or a media device,such that they fit snugly, but also stretch and conform to the exteriorof the case. Cases comprising the present pads can provide lightweight,flexible and impact-resistant protection, and move heat away from thedevice contained in the case.

In one exemplary embodiment comprising a continuously bonded multi-layerconstruction, the present pads and items including such pads provideitems that are rugged, durable, and able to withstand the temperatures,detergents and mechanical action used in industrial and/or commerciallaundering, unlike other padded clothing, which tends to degrade undersuch harsh conditions. The presence of the continuous bond between thelayers in the hinges is advantageous because it “locks” the medallionsin place, minimizing or preventing the egress of cushioning materialfrom the pad or, alternatively, minimizing or preventing the ingress ofmaterials, such as fluids, into the pads. Therefore, the hingesstabilize the pads, particularly the cushioning material, such thatfluids and other materials are not able to penetrate the pad, whichmight otherwise lead to delamination. The presence of the vents, whichare also continuously bonded, maximizes the breathability andventilating ability of the pads, without compromising the durability andwashability of the pads.

FIGS. 1-6, when taken together, illustrate a section 100 of cushioningmaterial according to the present disclosure. For ease of discussion,section 100 will be referred to hereinafter as “pad 100”. As shown, pad100 comprises a front surface 10, a back surface 12 and a perimeter 14.Pad 100 further comprises a plurality of cushioning regions 20, spacedapart and interconnected by a plurality of channels 38, and at least onevent 30 disposed in the center each of the medallions 20.

For ease of discussion throughout the description, the “cushioningregion(s)” will be referred to hereinafter as medallion(s). Althoughillustrated with a plurality of medallions, it should be understood thatthe pad can comprise a single medallion, with at least one vent.Similarly, although illustrated with a vent in each of the plurality ofmedallions, it should be understood that it is not necessary for eachmedallion to comprise a vent. In the present embodiment, the pad 100 andthe cushioning region 20 are square, but it should be recognized thatthe pad 100 and the cushioning region 20 can comprise any shape, size orconfiguration as is practical or desired for a particular design orapplication. The size, shape, thickness and material composition of thepads, medallions and vents may be varied, depending on a number offactors including, but not limited to, desired amount of flexibility forthe pad, the desired amount of impact resistance, the desired amount ofbreathability, etc. In addition, the configuration of the medallions maybe varied, and more than one type of medallion shape or vent shape maybe used in the pads.

As shown in FIGS. 6 and 7, pad 100 comprises a cushioning layer 15disposed between optional outer and inner layers 16,17. In the presentembodiment, the cushioning layer 15 is disposed between and encapsulatedby the optional outer layer 16 and optional and inner layer 17. Outerlayer 16 defines the contours of the medallion, defining an uppersurface 34 and an exterior sidewall 36 extending downwardly from theupper surface 34 to the upper surface 10 of the channel 38. Similarly,the outer layer 16 defines a vent sidewall 37 extending downwardly fromthe upper surface 34 to inner layer 17. If desired, the sidewalls 36, 37may be perpendicular to the upper surface 34, or have an angled profilerelative to the upper surface 34. If desired, and as shown, the uppersurface 34 may be radiused at the transition region “TR” between theupper surface and the sidewalls 36, 37.

As noted above, the plurality of medallions 20 are spaced apart andinterconnected by a plurality of channels 38. For each of discussion,the “channels” will be referred to hereinafter as hinges throughout thedescription. As shown in FIG. 7, hinges 38 have a width “W₁” defined bythe spacing between the perimeter of adjacent medallions, a depth “D₁”defined by the spacing between the upper surface 34 of the medallionsand the upper surface 10 of the pad 100, and a thickness “T₁” defined bythe combined thicknesses of the inner and outer layers 16,17 and thecushioning material 15 disposed between the layers. The width W₁ of thehinges 38 can be varied as desired or needed, and can range from asnarrow as about 1 mil to about 1000 mils, or more. In some instances, itcan be desirable for the width “W₁” of the hinges to be as narrow aspossible, in order to maximize the protective features of themedallions, while maintaining the flexibility of the pads. Suchapplications would include applications in which maximum protection isdesired, or in which the hinge is intended to wrap around a corner.Where impact protection is desired, the width of the hinges can bedesigned to be narrower than the width of the object which would impactthe pad. In such instances, the width W₁ can range from about 1 mil toabout 10 mils, more particularly from about 3 mils to about 7 mils, andmore particularly still about 5 mils.

In other instances, in which the protective features are less important,it can be desirable for the width “W₁” of the hinges to be much wider,in order to maximize the aesthetic feature of the hinges, which can bemade to contrast in color with the medallions. In such instances, thewidth W₁ can be in the millimeter or centimeter range, or even greater,if desired.

The hinges 38 may be linear or curved, depending on the shape of themedallions. The depth of the hinges between the medallions may be thesame or different, and the depth may vary along the hinge. Both curvedand linear hinges may be used in combination in the pads, as in thepresent embodiment, and may include a combination of curved and linearhinged areas.

In the present embodiment, the thickness of the cushioning layer 15disposed between the upper and lower layers 16,17 in hinges 38 may beminimized during the manufacturing process, such that its thicknessapproaches zero in the hinges 38. As a result, the cushioning materialin the hinges 38 may not be visible to the naked eye, or detectable onlyusing very sensitive thickness gauges.

The residual cushioning material 15 remaining in between layers 16,17,if any, assists in bonding layers 16,17 together in the hinges 38.Depending on the materials used, the bonding between layers 16,17 may beat least partially a chemical, thermal and/or mechanical bond. Forexample, if the material used as the cushioning layer is a resin, theresidual resin in the hinges 38 can function as an adhesive to bondlayers 16,17 together. Use of the resin as a bonding agent isadvantageous, because it eliminates the need for a separate adhesive inthe relatively thin hinge areas, and it keeps the bond consistent andequally flexible throughout pad, thereby enhancing the durability of thepad.

Alternatively, if a fabric is used as one of layers 16,17, the bondbetween the layers in the hinges may be at least partially mechanical,as a result of the resin being squeezed into opening or pores in thefabric, such that portions of layers 16,17 bond during manufacturing,resulting in “islands” of bonded layers 15,16,17 disposed betweenislands of bonded layers 16,17.

By minimizing or eliminating any residual cushioning material 15 inhinges 38, the flexibility of the hinges is maximized, such that theentire pad 100 is capable of bending, flexing, folding and twisting in avariety of direction.

As noted above, the outer and inner layers 16,17 are optional, but theymay be desirable for many reasons, particularly when the cushioninglayer 15 is a cellular material, and/or is a material that does noteasily retain its shape.

For example, in the embodiments described above, both the outer andinner layers 16,17 are continuously bonded to cushioning layer 15 acrossthe entire pads, including in the hinges. Depending on the constructionof the pad, the outer and inner layers may be bonded to cushioning layer15, or they may be bonded to each other, when the amount of material inthe hinges is minimized or eliminated. One advantage of bonding thefront layer to cushioning layer 15 is to provide a continuous,uninterrupted surface above and below cushioning layer 15 i.e., toencapsulate cushioning layer 15, other than at the perimeter of the pad.The continuous upper and lower layers strengthen the hinge and grooveareas, minimizing breakage in the hinges and/or grooves, which mayotherwise occur due to the flexing of the pad during use, because thehinges and/or grooves are thinner than the medallions. At least onebonded layer may be used for the protection of the thin hinge areasduring flexing. A thermoplastic polyurethane film, when used as theouter layer 16, is desirable for preventing cracking or breaking oflayer 17 in the hinges or grooves. The inner layer can also providestrength to the hinges or grooves if bonded to the foam, or in manyembodiments, both inner and outer layers are bonded to the foam. Incases where the hinge thickness is very low, especially with little orno cushioning material in the hinge, both inner and outer bonded layersare desirable to maintain the structural integrity of the pads. It isdesirable to use a material with substantial elasticity for the innerand outer layers, such as TPE films, spandex fabrics, and the like. Insome embodiments, the use of a fabric with a laminated film backing maybe desirable as an inside or outside layer. An inner layer that is alaminate of a fabric and a film, such as a polyurethane film laminate,can be very desirable for maximizing the durability of the hinges.

Optionally, and as disclosed in co-pending and commonly owned U.S.application Ser. No. 13/208,229, filed on Aug. 11, 2011, which isincorporated herein by reference in its entirety, the upper surfaces 34of the medallions may be contoured using a variety of geometries,including planar surfaces, curved surfaces, and combinations of planarand curved surfaces. Alternatively, the upper surface 34 of a medallionmay comprise a surface that is defined by a thickness that generallydecreases radially toward the perimeter of the medallion, or toward theperimeter of the pad.

The present pads may be manufactured using techniques disclosed in U.S.Pat. No. 7,827,704 and U.S. Publication Nos. US 2008/0034614 and US2009/0255625, which are incorporated herein by reference in theirentirety. The molds for the present pads are designed to allow layers15,16,17 to be compressed together under conditions sufficient tominimize or eliminate the foam in the hinges 38,50,60, for certainembodiments of the pads, while allowing the layers to bond together,which may be a chemical, thermal and/or mechanical bond.

FIGS. 8-9, when taken together, illustrate another embodiment of anexemplary cushioning pad 200 according to the present disclosure. Pad200 has a similar structure to pad 100, with the addition of a pluralityof vents 40 (hereinafter referred to as “hinge vents”) disposed in thehinges 38 between the medallions 20. The hinge vents are a variation onthe medallion vents, and another method to maximize the ventilation ofthe pad, as well as to decrease the weight of the pad. The hinge ventscan be used alone or in addition to the medallion vents 30. In thepresent embodiment, hinge vents 40 are circular, but as noted above, anysize or shape can be used.

FIGS. 10-12, when taken together, illustrate another embodiment of anexemplary cushioning pad 300 according to the present disclosure. Pad300 has a similar structure to pad 100, with the addition of a pluralityof hinge vents 50 disposed in the hinges 38 between the medallions 30.In the present embodiment, hinge vents 50 are linear, but as notedabove, any size or shape can be used. Also in the present embodiment,the hinges may be relatively narrow in comparison to other embodiments,which improves the flexibility of the pad, particularly if the padincludes the optional inner and outer layers, and when the inner and/orouter layers are stretchy and/or elasticized.

FIGS. 13-15, when taken together, illustrate another embodiment of anexemplary medallion 60 according to the present disclosure. Medallion 60has a structure similar to medallion 30, with the addition of aplurality of grooves 42 formed in the upper surface 34 of themedallions, extending from each of the external sidewalls 36 to the ventsidewall 37. The grooves 42 are fluidly connected to the vent, whichimproves the flow of air to and from the vent 30, as well as decreasesthe weight of the pad. In addition, like the hinges 38, the grooves 42increase the flexibility of the pad, and as the thickness of thecushioning layer 15 in the grooves 42 is decreased, the flexibility ofthe grooves 42, and pad 100, increases, as does the breathability of thepad.

The width, depth, orientation and position of the grooves 42 in theupper surfaces 34 of the medallions may be varied, depending on a numberof factors including, but not limited to, the desired direction andamount of flexibility, and the like. However, in order to maximizebreathability, fluid connection to the vent is desirable. The width,depth, orientation and position of the grooves 42 may vary, againdepending on a number of factors including, but not limited to, thedesired amount of bending for the pad and/or medallion in which thegroove is formed, the desired breathability of the pads, and the like.The grooves 42 are designed to be thicker than the hinge areas, butthinner than the medallions, at the thickest point of the medallions.Thus, groove thickness can range from about 10 percent (%) to 95% of themedallion thickness, about 20% to about 75% of the medallion thickness,and more particularly still about 50% of the medallion thickness. Alsoin any pad according to the present disclosure, the grooves 42 aredesigned allow the pad to bend in targeted areas, and to provide airflowwhen fluidly connected to the vents.

Like hinges 38, the grooves 42 may be curved grooves, or linear groovesthat are disposed along parallel and/or intersecting axes. Both curvedand linear grooves may be used in combination, and the grooves mayinclude both curved and linear regions. The thickness of the grooves ina pad or in a medallion may be the same or different, and the thicknessmay vary along the length of the groove, and from groove to groove.

FIGS. 16-18, when taken together, illustrate another embodiment of anexemplary medallion 70 according to the present disclosure. Medallion 70has a structure similar to that of medallion 60, but with a hexagonalstructure, rather than a square structure. Medallion 70 also includes aplurality of grooves 42 formed in the upper surface 34 of themedallions, extending from each of the outer hexagonal sidewalls 36 tothe vent sidewall 37.

FIG. 19 illustrates another embodiment of an exemplary medallion 80according to the present disclosure. Medallion 80 has a structuresimilar to medallion 30, with an octagonal structure, rather than asquare structure.

FIGS. 20-21, when taken together, illustrate another embodiment of anexemplary medallion 80′ according to the present disclosure. Medallion80′ has a similar structure to medallions 60,70, with an octagonalstructure, rather than a square or octagonal structure. Medallion 80′also includes a plurality of grooves 42 formed in the upper surface 34of the medallions, extending from each of the outer octagonal sidewalls36 to the vent sidewall 37.

As described above, another aspect of the present disclosure is theintegration of the above-described pad into garments, particularlycompression garments, to protect specific areas of the body. When one ofthe foregoing pads is integrated into a compression sleeve or garmentthat is tightly fitting to the wearer, the hinged and/or groovedmultilayer pad structure is sewn, adhered or otherwise attached to aspandex fabric or otherwise stretchable material in such a way that thehinged pads are held in form fitting contact with the area to beprotected. The pad can be sewn to the inside or outside of a garment. Itmay be desirable to have the pad cover only a portion of the fullcircumference of the sleeve, so that the sleeve can still stretch to fitthe wearer. The integration of the protective pad with the compressiongarment provides a simple and inexpensive method for adding protectionfor specific body areas, without altering the entire garment.

When the pad is integrated with a compression sleeve, some uniqueproperties and advantages are provided in comparison to other methods ofprotecting moving joints. When integrated into a compression sleeve, thepad can be in continuous form fitting contact with the joint to beprotected, which may be desirable when protecting flexible joints suchas knees, elbows, shoulders and ankles, because the selection ofsuitable hinges allow the protective sleeves to naturally remain in thecorrect position and orientation. With a suitable selection of hingesand placement of sleeve on the garment, the protective compressionsleeve moves as one with the limb, allowing much wider range of motionthan traditional padding.

When the protective sleeve is positioned in form fitting contact withthe user's body, the possibility of additional injury to the user by anyimpact caused by the pad hitting the user is minimized. Stiffer pads maynot be capable of form fitting continuous contact with the user's bodyarea or joint, because they are not sufficiently flexible. If notform-fitted, the pads may become part of the impact that injures thewearer. Pads in a sleeve configuration provide improved protection for amoving joint, because they can wrap around a wide radius, and in someinstances provide 360 degrees of protection by wrapping the entirejoint. In general, it is desirable to leave some area of the compressionsleeve without the additional padding layers, to allow the sleeve tostretch and conform to the arm.

In some embodiments, it can be desirable for the garments to be madefrom a wicking fabric that is designed to move moisture away from theskin layer.

The present pads also may be designed to enhance air and/or moisturetransmission, without significantly compromising protection, which maynot be an option with other protective padding. The use of vents, asdescribed above, in the hinges, grooves and/or medallions enhancesmoisture and/or air transmission rates. The use of a spacer fabric orwicking fabric as the inner layer or in combination with a TPE filmlayer as the inner layer, can enhance comfort as well and wick moisturethrough the hinges. Also, the use of a high moisture vapor transmissive(“MVT”) film layer can further enhance comfort. Such films can functionby chemical absorption/desorption. Examples of such films are availableunder the product name Sympatex, or TX1540 from Omniflex. The use ofmicroporous high MVT films such as Goretex or Porelle (by Porvair) canalso be used, or other similar films.

FIGS. 22-23, when taken together, illustrate another embodiment of anexemplary elbow pad 500, which may have the same construction as any ofthe foregoing embodiments, and an optional flange. In the presentembodiment, the pad comprises a plurality of round vents 30, disposed inthe channels, grooves and in the flange.

FIGS. 24-25, when taken together, illustrate another embodiment of anexemplary elbow pad 500, which may have the same construction as any ofthe foregoing embodiments, and an optional flange. In the presentembodiment, the pad comprises a plurality of round vents 30, disposed inthe channels and in the flange. In the present embodiment, the thicknessof the cushioning material in the channels and flange have beenminimized or eliminated.

FIG. 26 illustrates another embodiment of an exemplary elbow pad 600, asdisclosed in the '229 application, which also comprises a plurality ofcurvilinear vents 30. The curvilinear vent shapes shown in the presentembodiment provide improved movement and stretch in the curvilinearvented areas, while maintaining the otherwise “encapsulated medallion”structure provided by a bonded multi-layer construction.

In any or all of foregoing embodiments, the pads may comprise anoptional perimeter flange 40′ (see FIGS. 22-26) defined in the uppersurface 10 to maintain the medallions in spaced apart relation from theperimeter of the pad. The optional perimeter flange 40′ can comprise awidth “W₂” defined by the spacing between the perimeter of the outermostmedallions and the perimeter 14 of the pads. The width W₂ of theperimeter flange 40′ may vary, as desired. The perimeter flange 40′ canbe thinner than the medallions, allowing the pad to be attached to itemssuch as clothing along the flange area using a variety of techniques,such as by sewing, gluing, welding, bonding, heat sealing, and the like.When integrated with, for example, a compression sleeve, the pad can besewn, glued or otherwise attached to the outside of the sleeve fabric atthe flange, or it can be sewn or attached to the interior surface of thesleeve, and exposed through a corresponding opening in the sleeve.

It should be understood that the flange is not necessary to the pads,and that the pads may be attached to an underlying surface using othermeans, such as by sewing, gluing, welding, heat sealing, bonding, andthe like.

In any or all of foregoing embodiments, the cushioning layer 15 cancomprise one or more layers of any material or combination of materialshaving sufficient structural integrity to be formed into predeterminedshapes, such as by molding, and that are capable of withstanding theenvironment in which they are intended to be used, without substantialdegradation.

The material type and composition can be selected to provide articlesand/or regions of articles with predetermined material characteristics,which can be used to customize the pads for specific applications suchas cushioning, impact resistance, wear resistance, and the like.Examples of suitable materials include polymeric materials, compositematerials, and the like. Examples of suitable polymeric materialsinclude, but are not limited to, thermosetting polymeric materials,elastomeric polymeric materials, thermoplastic materials, includingthermoplastic elastomeric materials, and combinations comprising atleast one of the foregoing. Some possible polymeric materials include,but are not limited to, polyurethane, silicone, and/or the like, andcombinations comprising at least one of the foregoing materials.

In some instances, it may be desirable for the pad to have cushioningcharacteristics to provide a soft, pliable and comfortable feel such aswhen used in contact with a body. In such instances, it has been foundthat some polymeric gels may be suitable. One example of a suitablepolymeric gel is a polyurethane gel comprising a durometer ranging fromabout 0.01 Shore 00 to less than or equal to about 70 Shore A, moreparticularly less than 70 Shore 00, more particularly still less than 60Shore 00. The material can comprise a durometer ranging from about 30Shore 000 to about 88 Shore D. The durometer of the polymer can bedetermined by those of ordinary skill in the art using tools such asdurometers or penetrometers. Formation of the gel can take place by avariety of methods known to those of skill in the art. For example,formation of a polyurethane gel can comprise reacting suitablepre-polymeric precursor materials e.g., reacting a polyol and anisocyanate in the presence of a catalyst.

In some instances, it may be desirable for the pad to be lightweight,and in such instances, the cushioning material 15 may comprise a foammaterial, such as a low density foam material. Examples of suitable lowdensity foams include polyester and polyether polyurethane foams.

In some instances, it may be desirable for the pad to be capable ofproviding impact resistance. In such instances, various types of impactabsorbing materials have been found suitable for the cushioningmaterial, particularly energy absorbing foams. For such applications, itcan be desirable for such foams to have a density ranging from about 5to about 35 pounds per cubic foot (pcf), more particularly from about 10to about 30 pcf, and more particularly still from about 15 to about 25pcf. Suitable rate dependent foams are available from Rogers Corporationunder the brand names PORON® and PORON XRD®, which are open cell,microcellular polyurethane foams.

In all of the foregoing embodiments, the optional outer layer 16 cancomprise any material capable of providing sufficient elasticity toprevent tearing and/or stretching when a force is applied thereto;sufficient structural integrity to be formed into predetermined shapes;and that is capable of withstanding the environment in which it isintended to be used (e.g., repetitive deformations such as twisting,bending, flexing, stretching, and the like), without substantialdegradation. The outer layer 16 also can be selected to facilitate thehandling of layer 15, which can comprise adhesive characteristics, insome instances. Therefore, the outer layer 16 can be selected to providea relatively non-tacky surface and smooth surface to the human touch,after molding.

Outer layer 16 can comprise any thickness, and the thickness can bevaried depending upon the application. The desired thickness for aparticular application can be determined using routine experimentationby those of ordinary skill in the art. Outer layer 16 can comprise athickness ranging from about 0.2 milli-inches (hereinafter “mil”) toabout 60 mils, more particularly from about 0.5 mils to about 30 mils,and more particularly still from about 1.0 mil to about 15 mils.

In instances in which the hand-feel of the products is important, it hasbeen found desirable to minimize the thickness of the outer layer.Therefore, in such products it can be desirable to use the thinnestouter layer possible without sacrificing durability. For example, forapplications in which a relatively thin outer layer 16 is desirable, itcan comprise a thickness ranging from about 0.2 mil to about 6 mil, moreparticularly from about 0.5 mil to about 3 mil, and more particularlystill from about 0.6 mil to about 2 mil.

In some instances, it can be desirable to use a thicker outer layer 16,which can provide increased durability in comparison to thinner outerlayers. For example, when the present materials are used in vibrationdampening applications, it can be desirable for the thickness of theouter layer 16 to be about 50 to about 60 mil. Alternatively, thickerlayers can be desirable when the cushioning layer is tacky, because thetacky material can be exposed if the outer layer 16 is punctured, makingthe products difficult to handle.

When the present products are formed using a thermoforming process, itcan be desirable to use an outer layer having a thickness of up to about⅛ inch, and even thicker in some instances when desired or necessary. Ithas been found that it is possible to maintain very soft pliability forouter layers having a thickness of as much as 6 mil or more by applyingheat and/or a vacuum during the thermoforming process.

Outer layer 16 also can comprise a support layer (not illustrated),which assists in handling the material. Alternatively, the outer layermay also be applied as a coating of material during or after the moldingprocess, using a variety of techniques known to those of skill in theart.

Suitable materials for the outer layer 16 include plastics, elastomericmaterials such as rubber, thermoplastic elastomers (“TPE”), and/or thelike, and combinations comprising at least one of the foregoingmaterials. Examples of plastics that can be used for the outer layerinclude, but are not limited to, ethylene-vinyl acetate (“EVA”), nylon,polyester, polyethylene, polyolefin, polyurethane, polyvinyl chloride(“PVC”), polystyrenes, polytetrafluoroethylene (“PTFE”), latex rubber,silicone, vinyl, and combinations thereof.

Other possible materials for the outer layer 16 include a variety ofother synthetic and/or non-synthetic materials including, but notlimited to, paper, fabric, spacer fabrics, metal, metallized plastic,plastic film, metal foil, and/or the like, as well as composites and/orcombinations comprising at least one of the foregoing. Other durablematerials can be used for the outer layer including knit, woven andnonwoven fabrics, leather, vinyl or any other suitable material. Use ofa spacer fabric as the outer layer can maximize the airflow.

It can be desirable to use materials for the outer layer than aresomewhat elastic; therefore, stretchy fabrics, such as spandex fabrics,can be desirable. The use of stretch fabric as the outer layer can bedesirable because it can improve the flexing of the hinges and grooves,and the forming of the outer layer into a contoured shape. In somecases, heating or otherwise forming or pre-stretching materials withmore limited stretch, can improve the final product.

When outer layer 16 comprises a fabric layer, the fabric can be knit,woven, non-woven, synthetic, non-synthetic, and combinations comprisingat least one of the foregoing, and the fabric layer can be laminated to,for example, a TPE film. When the pad application requires stretch, thenuse of an outer layer with elongation may be desirable, and when theouter layer is a laminate, it may be desirable for each layer in thelaminate to elongate.

As noted above, it can be desirable to use materials for the outer layerthan are somewhat elastic, such as the TPE materials mentioned above.Such TPE materials also can be desirable because they are available asfilms, in relatively low thicknesses. Any film thickness can be usedprovided it is compatible with the method of molding and suitable forthe intended application, but film thicknesses of between about 1 miland about 10 mils are desirable. Thicker films are more durable, butthinner films are less expensive, and may provide a softer feel. Thereare other reasons to choose thicker films, such as when thermoformingdeeper shapes, to improve the molding process. The use of a film ratherthan a fabric as the outside layer can make the product easy to cleanand protect the cushioning material from damage and dirt. The films cancomprise an elongation of about 100 percent (%) to about 1500%, moreparticularly about 200% to about 1000%, and more particularly stillabout 300% to about 700%”.

Some possible TPE materials include styrenic block copolymers,polyolefin blends, elastomeric alloys, thermoplastic polyurethanes,thermoplastic copolyester, thermoplastic polyamides, and combinationsthereof. Examples of commercially available elastomeric alloys includemelt-processable rubbers and thermoplastic vulcanizates. Examples ofsuitable TPEs include thermoplastic polyurethanes (“TPU”). TPU film canbe desirable due to its combination of durability, elasticity, softnessand flexibility. One suitable film is a polyester polyurethane filmavailable from Deerfield Urethane, a Bayer Material Science Company,under the product name Dureflex PS5400. It can be desirable to use apolyester TPU film, rather than a polyether TPU film, because thepolyester TPU film, in addition to having improved abrasion resistancein comparison to polyether TPU film, also performs unexpectedly wellunder high humidity conditions, such as in athletic clothing andcommercial laundering.

Additionally, pads and garments can be manufactured with both fabric andfilm on different parts of the pad, allowing for full range of motionand further protection from the use of both materials. It may bedesirable that the outer layer be a composite of a fabric and film sothat the film aids in protecting the hinge during flexing and can alsoserve as a protective barrier for the cushioning material.

In any or all of foregoing embodiments, inner layer 17 can comprise thesame materials as the outer layer 16. When inner layer 17 comprises afabric layer, the fabric can be knit, woven, non-woven, synthetic,non-synthetic, and combinations comprising at least one of theforegoing, and the fabric layer can be laminated to, for example, a TPEfilm. When the pad application requires stretch, then use of an innerlayer with elongation may be desirable, and when the inner layer is alaminate, it may be desirable for each layer in the laminate toelongate. Use of a fabric layer as inner layer 17 can be advantageousbecause it can trap and disperse air bubbles that may otherwise form inor between the layers, resulting in a better appearance for the finalmolded products.

The use of active agents in one or more of the inner layer, outer layerand/or the cushioning layer can be desirable. For example, the additionof a silver or copper based active agent can provide the material withantimicrobial or antifungal properties. The use of actives in the inneror outer layer or the foam itself can be desirable, such as the additionof silver or copper based actives to act as an antimicrobial orantifungal agent.

One or both of inner and outer layers 16,17 also can comprise color,graphics and/or indicia, including text. The color, graphics and/orindicia disposed on such layers can be transmitted through other layerswhen they are formed from colorless and/or transparent materials, whichcan be desirable for aesthetic and costs reasons. In addition, ifdesired, one or both of inner and outer layers 16,17 also can befluid-permeable. “Fluid-permeable,” as used herein, means that thematerial from which the layer is formed is open to passage or entranceof a fluid material.

The size, shape, configuration, orientation and dimensions of the pad,medallions, medallion contours, hinges, grooves and flange may be variedas desired in order to achieve the desired characteristics for the paddesign. All of the foregoing features, alone or in combination, aredesigned to facilitate the flexibility of the pad either inwardly oroutwardly to conform to a user's body during movement. However, itshould be understood that in each of the foregoing embodiments, and inany pad according to the present disclosure, all of the foregoingmeasurements can vary depending on the desired characteristics anddesign of the pad. For example, the pads are designed to provide avariety of characteristics such as, but not limited to, cushioning,breathabiltity, ventilation, vibration dampening and/or impactabsorption, and the like. The characteristics of the pad may be variedby changing the thickness and/or material type of cushioning layer 15 inthe medallions, changing the size, shape, number and position ofhtevents; changing the spacing between the medallions (i.e., the width ofthe hinges), and/or changing the contours of the medallions, and thelike. For example, using a gel for cushioning layer 15 provides a padwith cushioning and vibration dampening characteristics; using a foamdecreases the weight of the pad; using a rate dependent or impactabsorbing foam increases the impact absorption of the pad; etc. Ingeneral, increasing the thickness of the cushioning layer 15 in themedallions generally increases the foregoing characteristics; and usinga combination of materials for cushioning layer 15 may provide acombination of characteristics.

In any or all of foregoing embodiments, and in any pad according to thepresent disclosure, the hinges are designed provide flexibility to thepad in targeted areas in which flexibility is desired or needed. Usingcurved, parallel and/or intersecting hinges allows the flexibility ofthe pad to be tailored to specific functions, such as protecting jointsduring motion. The width, depth, orientation and position of the hingesmay vary, depending on a number of factors including, but not limitedto, the desired amount and location of flexibility for the pad.

The flexibility of the hinges can be varied, by varying the thickness ofthe material in the hinge regions. For example, decreasing the thicknessof the material in the hinges increases the flexibility of the pad, andincreasing the thickness of the material in the hinge regions decreasesthe flexibility. In some embodiments that include one or both of theinner and outer layers 16,17, it is possible to “squeeze” the cushioninglayer 15 in the hinges to minimize or eliminate the amount of materialin the hinge region. In such embodiments, the flexibility can bemaximized or improved by minimizing the thickness of the cushioninglayer 15 in the hinges, or when the pad is molded without cushioninglayer 15 in the hinges 38. For example, when using inner and outerlayers 16,17 with thicknesses of about 4 mils, it is possible to achievehinge thicknesses approaching 8 mils, or approaching the combinedthickness of the inner and outer layers 16,17, by removing as muchcushioning material 15 from the hinge area, as is possible during themolding process.

To maximize flexibility in laminated structures, it is desirable to usea hinge depth of less than about 20% of the medallion thickness, moreparticularly less than about 10% of the medallion thickness, and moreparticularly still less than about 5% of the medallion thickness.Successful parts have been made with hinge depths of 0.020″, 0.040″ andup to 0.080″.

When the pads are molded with an optional inner and/or outer layer, orboth layers, the maximum pad flexibility may be achieved when the hingethickness approximately corresponds to the combined thickness of thelayer(s) other than layer 15, or when the thickness of the cushioninglayer 15 is minimized and approaches zero.

Deep hinges can also have some foam thickness, and still provide greatmobility. As noted below, one feature of the present protective pads isthat the outer and/or inner layers can protect the cushioning layer frombreaking at the relatively thin hinge regions during repetitive flexing,so the foam thickness is not limited by the foam flex strength, as longas the foam is bonded to either or both inner and outer layers.

In each of the foregoing embodiments, and in any pad according to thepresent disclosure, the width of the hinges, or spacing between themedallions, is designed allow the pad to bend as much as possible, whilestill retaining the protective characteristics of the medallions.Therefore, the spacing between the medallions can be determined by theamount of distance needed to have a flexible hinge, without exposing toomuch space between the medallions, such that injuries would occur whenthe gap between the medallions is impacted. Thus, maximum protection maybe achieved using a hinge width of less than about 20% of the medallionthickness, more particularly less than about 10% of the medallionthickness, and more particularly still less than about 5% of themedallion thickness. As noted above, the use of angled or saw-toothedshaped hinges and/or grooves (not illustrated) can also reduce theamount of exposed unprotected surface.

In any or all of foregoing embodiments, the pads may be formed such thatthe foam has a generally uniform density throughout the pad.Specifically, in some instances it may be desirable to minimize compressthe foam in the grooves or hinges during molding or forming, because thecompression increases the density of the foam, which tends to reduce therange of motion and provide non-uniform padding levels by eliminatingfoam. The contoured medallions and variations in foam thickness not onlyprovide an aesthetically pleasing pad, but they also provide the abilityto maximize protection where it is most needed, and reduce protectionwhere it is needed less. By using uniform foam density and varyingthickness where needed, the weight of the pad is reduced, and the rangeof motion is increased. Using thermoforming or compression to take foamand compress areas to shape may increase density in those areas andcreate additional weight, uneven protection and less range of motion.

The present cushioning materials provide advantages over othermaterials. The present vented cushioning materials can be used to makebreathable, low profile, conformable protective padding and clothing forathletes. Such pads and clothing are breathable, allowing thetranspiration of sweat and air. In addition, in some embodiments, theindividual cells of the padding can move independently of one another.

Padding and garments made from the present vented cushioning materialare washable, durable and have improved breathability in comparison tosuch padding without venting. In addition, the protective capability ofthe present padding is increased in comparison to comparable structuresthat do not include vents, because the vented medallions and padding mayabsorb more energy, due to the ability of the walls to move, as well asto collapse. When rate dependent materials are used to form the padding,the vented construction provides increased area for shock or energytransmission to the rate dependent material.

The pad construction, when inner and outer film layers are used in thepad, allows the manufacturer to reduce the width of the spacing betweenthe cushioning regions, because it is not necessary to use fabric tolocate and position the pad. This also allows the manufacturer to angleand design the shape of these grooves and hinges to cover and protectthe user during the complete range of movement while stretching,fitting, and remaining in place during the activity.

The ability to create an exposed or exoskeletal protective pad, incontrast to a pad enclosed in a pocket, offers advantages forindividuals wearing supportive or corrective braces, such as kneebraces, ankle supports, back supports, and the like. Thus, the pads canbe attached or adhered to mechanical supports to protect adaptivemobility athletes from themselves and from other athletes with similarbraces. Similarly, the design of pads according to the presentdisclosure can be customized and adhered to braces worn by conventionalathletes. This provides protection to both the wearer of the brace butalso other athletes who come in contact with the corrective brace. Oneexample of such a brace is the padding on knee braces used inprofessional football.

The present pads can also be used on shin guards worn by youth, adultand professional soccer players. The properties of impact absorbing foampadding in combination with form fitting garments provides unique andhighly accurate protection of targeted body parts. Therefore, oneembodiment of this disclosure is flexible, form-fitting breathable shinand ankle guards for soccer players. Such shin and ankle guards providemore protection to soccer players due to the closer fit of the foam,more comfort from the wicking materials, venting and perforation used inconstruction, and a more durable product than, for example,non-breathable, hard plastic pad held in place with straps, or frictionof the user's sock.

The foam padding and other layers as noted earlier can be designed withperforations either throughout the material, or within the groove orhinge areas, with minimal or no deterioration of the impact protection.The fact that all layers of the pad are continuously bonded together, insome embodiments, allows the transpiration of water vapor through thepre-established pathways rather than absorption into the pad. Once themoisture is wicked into the fabric layer, it can be channeled outthrough the pads because the surfaces are bonded. In contrast, otherpads may have one or more of the layers free floating, making them moreuncomfortable to wear.

In certain embodiments, the fact that the outside surface (fabric orfilm) is (in some embodiments) the actual outside surface of the garmentor sleeve is an important distinction. Pads that have unbonded fabric orother covering sewn across the outside, covering the padding, allowslippage of the outer layer across the padding on impact, which affectsthe precision of the impact protection. When wearing the currentgarments according to the present disclosure, the wearer has the pad onthe exterior of a form-fitted garment, which provides more accurateprotection of the specific body area or joint. Having the exposed outerlayer of the present disclosure pad as the outside layer of the garmentor sleeve (as shown in FIGS. 12 and 13), also allows improved moistureor air flow management, which is improved to cut foam pieces with anyform of loose cover. Precision vents and air channels minimize heat andmoisture build-up. In addition, embodiments with the outside surface ofthe pad exposed allow for the inside of a form fitting garment to lieflat against the user's skin, as the inside surface of the pad cangenerally be flat. When attached to the outside of an elastic fabric,the user can have an uninterrupted layer of elastic fabric or othermaterial against the skin. This allows the pad to closely hug the skinsurface, and also to have a more seam-free interior surface which isless likely to cause abrasions or irritations to the skin.

Use of the pads exposed on the surface also provides improved ability tomake hinges or grooves tighter and/or smaller because an add-on externalmaterial could otherwise block flexing by filling in the hinge spacesand interfering with the movement of the hinges. The grooves and hingescan also be angled and shaped in specific designs to cover and protectthe subject more precisely. The creation of specific and moreaerodynamic shapes can also be made on the garment surface using thepresent pads. The aerodynamic surface, combined with protection, can bean advantage in sports such as ski racing, in which the wearer would beprotected, for example from impacts with gates, while having enhancedlower wind resistance. Other sports can benefit from improvedaerodynamics, such as bike racing.

Use of the present impact absorbing pads, when exposed on the surface ofa garment, allows the impact absorbing foam to react faster, because iteliminates layer(s) between the pad and impact. This can be a desirablefeature when using “rate dependent” impact absorbing foams, such asPoron XRD, or other such materials that stiffen on impact, and the useon the exposed surface with only a single layer of bonded film or othermaterial between foam, and the object impacting the pad allows the foamsto react better and more quickly.

In some embodiments, the use of film, particularly polyesterpolyurethane film, as the outside layer of a pad attached to a sleeve orgarment, creates a durable and more washable pad system. The exteriorsurface, with the film exposed, can be both durable and dirt resistant.Fabric as a top layer, whether sewn or otherwise attached, can rip andtear or get dirty, can be difficult to clean. Fabric and/or film that iscontinuously bonded as an inner or outer layer, either together in thehinge areas, or to the cushioning material in the medallions, is moredurable than unbonded sewn fabric used in many pads, in which a tornouter garment exposes the pad meant to protect the wearer, and subjectsit to dislocation or removal from the garment. In the embodiments of thepresent disclosure that use a fabric layer as the inner or outer layer,a film layer inside the fabric can also minimize and/or prevent dirt orliquid from infiltrating or penetrating the foam.

The fact that the pads in many embodiments are molded with uniformdensity of foam padding (i.e., not higher density compressed foam)allows more precise design of the protection, and greater range ofmotion than varied densities caused by compression.

The present pads, clothing and methods of manufacture are advantageousfor many reasons. For example, a single continuous pad with manyelements provides an economic advantage over traditional padconstruction techniques, by eliminating labor-intensive cutting, scoringor thermoforming that may otherwise be required for end garmentconstruction.

Some embodiments have hinge areas near zero while others are at 0.010″(10 mils), 0.020″ (20 mils) or even 0.080″ (80 mils) or 0.120″ (120mils).

The use of a bonded inner layer with elasticity and a bonded outer layerwith elasticity is also desirable in embodiments where stretch isdesired, such as when the cushioning pad is attached to a stretchgarment.

Where near the thickness of the hinge areas approaches zero, or in thinhinge areas (less than 0.100″ (1 mil) foam), the fact that the entirepad has a continuously bonded inner or outer layer (or both) maintainsspacing and prevents separation of an unprotected area. This is incontrast to pads in which separate cut pieces are used to create thepad, because the cut pieces can separate under stress or force and allowthe user to be exposed, and possibly injured.

In some embodiments, the use of narrow hinge spacing has proveddesirable to prevent exposed areas when the joint is flexed in certainways. The present disclosure allows very narrow hinges, or very narrowspacing between medallions, and minimizes the danger of the hingeseparating during use.

The present pads can be manufactured to provide better protection tospecific body areas while being lightweight, which is a significantadvantage to athletes and active individuals.

One advantage of the present protective pads is that an entire flexingregion can be protected by one pad or several pads designed specificallyfor a certain part of the body, rather than smaller cut pads or stripsthat are sewn into a garment. The continuously bonded large pad is bothmore economical, and also prevents shifting of the cut or strips of padsthat would cause gaps in protection. In addition to providing improvedand more accurate protection than current products, the presentprotective pads allow the entire durable pad to be exposed, which can beboth an aesthetic advantage and weight savings, and can make the padmore comfortable with better moisture or air transmission.

Those of ordinary skill in the art will recognize that other methods ofattachment may be used, but it has been found that sewing providescertain advantages. In contrast to heat sealing or welding, it has beenfound that sewing the cushioning pads in place along the perimeterflange prevents or minimizes the pads from separating from the garment,which is advantageous in comparison to pads that are loose within thegarment (i.e., held loosely in pockets designed to contain the pads), orthat are attached by sewing, gluing, welding, heat sealing, and thelike.

The foregoing pads are exceptionally durable, and can withstand repeatedcommercial laundering. In such pads, when incorporated into garments, itis theorized that the thickness of the perimeter flange (e.g., about 20mils) provides a sturdier region for stitching, which would otherwisewould fray and rip without the cushioning material if unsupported by the20 mil perimeter flange. Moreover, the perimeter flange makes a moreattractive product, with a softer edge than is possible by terminatingwith the film at the perimeter of the cushioning pad.

It is also thought that the near-zero hinges throughout the pad allowthe pad contribute to the durability of the pad during the washingcycle, because the foam material in the hinges is so thin, that acellular structure no longer exists. Thus, the stitched perimeter flangeprevents or minimizes the pad from lifting off in repeated washing,i.e., locking down the perimeter of the cushioning pad.

In addition, the continuous bonding of the inner and outer films eitherto the cushioning material in the medallion regions, or to each other inthe hinges, prevents or minimizes the chance of fluid or other materialsfrom getting into the pad, and of the cushioning material from escapingfrom the pads. In combination, both features enhance the durability ofthe many pads in rigorous conditions, eliminating or preventingcompletely the delamination of layers, as occurs in other products. Itis thought that the perimeter flange and adjacent near zero hingeprevent or minimize fluid and/or particulates from infiltrating the padsbeyond the perimeter flange, because the foam has been removed almostcompletely from the hinge area, and without the cellular structure ofthe foam in the hinge area, fluid and/or particulates cannot migratepast the perimeter flange. Therefore, the perimeter hinge acts as abuffer to the infiltration of fluid and/or particulates into the pad.

Similarly, the “network” of hinges throughout the cushioning pads,particularly when the hinges are “near zero” hinges, further improvesthe durability of the pads, because eliminating and/or minimizing thefoam, or other cushioning material in the hinge area, increases the bondstrength in the hinges. The bond strength is increased in the hinge areabecause the remaining cushioning material in the hinge areas isinsufficient to support the foam structure (in the case of a foam). Iffoam remains in the hinges, the bond strength may be limited to the foamtear strength. Thus, when the thickness of the foam or other cushioningmaterial, is minimized, the bond in the hinges increases, because thereare no thin foam cell walls to tear. That is, without a cellular foamstructure in the hinges, there is no space for fluid and/or particulatepenetration beyond the perimeter flange. As a result, if a singlemedallion or hinge is damaged or compromised, damage to the entire padis minimized or compartmentalized, because the damage may extend only tothe adjacent pad and/or hinge.

Another advantage of the present pads is that the combination of deephinges and less deep grooves, or multi-level hinging, provides aprotective garment with improved protection, while maintaining asignificant range of motion in the protected area. The use of connectedtop, bottom or both layers allows for the more precise use of the hingesand grooves, and keeps the individual medallions from moving relative toone another. In addition, the integration with stretchable form-fittinggarment material results in significant wrapping of the protected areaand keeps the exterior pad in continuous contact with the specific areaof the body.

It should be noted that the terms “first,” “second,” and the like hereindo not denote any order or importance, but rather are used todistinguish one element from another, and the terms “a” and “an” hereindo not denote a limitation of quantity, but rather denote the presenceof at least one of the referenced items. Similarly, it is noted that theterms “bottom” and “top” are used herein, unless otherwise noted, merelyfor convenience of description, and are not limited to any one positionor spatial orientation. In addition, the modifier “about” used inconnection with a quantity is inclusive of the stated value and has themeaning dictated by the context (e.g., includes the degree of errorassociated with measurement of the particular quantity).

Compounds are described herein using standard nomenclature. For example,any position not substituted by an indicated group is understood to haveits valency filled by a bond as indicated, or a hydrogen atom A dash(“-”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, —CHO is attachedthrough the carbon of the carbonyl group. Unless defined otherwiseherein, all percentages herein mean weight percent (“wt. %”).Furthermore, all ranges disclosed herein are inclusive and combinable(e.g., ranges of “up to about 25 weight percent (wt. %), with about 5wt. % to about 20 wt. % desired, and about 10 wt. % to about 15 wt. %more desired,” are inclusive of the endpoints and all intermediatevalues of the ranges, e.g., “about 5 wt. % to about 25 wt. %, about 5wt. % to about 15 wt. %”, etc.). The notation “+/−10%” means that theindicated measurement may be from an amount that is minus 10% to anamount that is plus 10% of the stated value.

Finally, unless defined otherwise, technical and scientific terms usedherein have the same meaning as is commonly understood by one of skillin the art to which this disclosure belongs.

While the disclosure has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

What is claimed is:
 1. A breathable cushioning pad, comprising: acushioning pad comprising a continuous upper layer with an uppersurface, a continuous lower layer with a lower surface, and a cushioningmaterial disposed between the continuous upper layer and the continuouslower layer, the cushioning pad comprising a cushioning region having athickness, the cushioning region comprising a cushioning materialdisposed between and continuously bonded to the continuous upper layerand the continuous lower layer; a channel disposed in the cushioning padand defining the cushioning region, the channel forming a hinge regionof the cushioning pad, the hinge region comprising a thickness less thanthe thickness of the cushioning region, the hinge region furthercomprising the continuous upper layer and the continuous lower layer,the continuous upper layer at least partially bonded to the continuouslower layer; and at least one vent extending through and in fluidconnection with the upper surface and the lower surface, wherein thevent is disposed in the hinge region.
 2. The breathable cushioning padof claim 1, further comprising a groove defined in the upper surface ofthe cushioning region, the groove comprising a thickness less than thethickness of the cushioning region and greater than the thickness of thehinge region.
 3. The breathable cushioning pad of claim 1, furthercomprising a perimeter flange and a perimeter channel defining aperimeter hinge adjacent to the perimeter flange, the perimeter flangehaving a thickness greater than the thickness of the perimeter hinge andless than the thickness of the cushioning region.
 4. The breathablecushioning pad of claim 2, further comprising a perimeter flange and aperimeter channel defining a perimeter hinge adjacent to the perimeterflange, the perimeter flange having a thickness greater than thethickness of the perimeter hinge and less than the thickness of thecushioning region.